UNDERWATER MAINTENANCE AND REPAIR IN LIEU OF DRY DOCKING. USS MIDWAY Museum Installation of Hull Suction and Discharge Blank Patches

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1 UNDERWATER MAINTENANCE AND REPAIR IN LIEU OF DRY DOCKING USS MIDWAY Museum Installation of Hull Suction and Discharge Blank Patches 1

2 Phoenix Who we are In Water Repair Capabilities The tool kit Hull Cleaning and Inspection U/W Welding U/W NDT (thickness, flaw detection) Cofferdams U/W Painting USS MIDWAY Museum Hull blanking Background Planning Blank Installation Process New Technology Summary Questions Underwater Solutions Worldwide Overview 2

3 Phoenix Founded in 1997 Employee Owned Specializing in Underwater Services Engineering, Diving and Remote Operated Vehicles Over 86 Underwater Welding Repairs to Active U.S. Navy Ships and Submarines in the past 5 years Underwater Welding -32 Underwater Weld Procedures (NAVSEA, ABS and AWS) Inspection and NDT Services U.S. Navy Support Services US Navy Diving Services Contract since 1997 Undersea Operations Contract since 2001 Submarine Rescue Maintenance and Operation since 2006 Underwater Solutions Worldwide 3

4 Cost Reduction Over Dry Dock U/W I, M & R Benefits No Transit Cost Difficulties of just getting away from the pier Dredging Mooring removal Tugboats No Lost Visitor Days No Dry Docking Cost you pay for the work, not the dry dock Lower Cost Enables a More Proactive I, M & R Process Incremental Process not all or nothing Phased work based on budget Sequentially address critical need items Shift Cost of Repair to the Work Not the dry dock 4

5 Getting Started Contractor Qualifications Corporate Quality Management System Safety Program NDT and Welding Procedures and Qualification Flexibility Cost & Schedule Equipment Surface Supplied Diving System Communications and Video Control Van Support Equipment - Welding, cutting, hydraulic tools Personnel Commercial Diver training and qualification NDT Qualification Welding Qualification Experience in the task Avoid SCUBA mitigate risk Hire Professionals Reduce risk of damage or injury 5

6 U/W Tool Kit Hull Cleaning - The first step in maintenance and inspection Problem Excessive growth prevents inspection and hides serious degradation Heavy calcareous growth can lead to coating failure during removal Solution Periodic removal of marine growth using either multi-brush or handheld machines Benefit Cleaning process allows a thorough inspection Caution and Concerns Unqualified operators can severely damage hull coatings Hull Cleaning The key to early problem identification 6

7 U/W Tool Kit Inspection Problem Hull thinning due to corrosion (interior and exterior) Cracks Wasting due to dissimilar metals (weld metal, bronze, brass, stainless steel) Solution Visual Inspection (VT) include color still photographs and video Ultrasonic Inspection Thickness (UTG) wet or dry localized and large scale mapping of plate thickness Magnetic Particle Inspection (MT) wet or dry examination of surface indications Ultrasonic Inspection Flaw (UTSW) wet or dry mapping of indications, detects subsurface cracking Inspection - First line of defense 7

8 U/W Tool Kit Inspection Benefits Locate problems when the fix is minor vs. major Plan and budget repairs well in advance Caution and Concerns Use qualified Inspectors American Society of Nondestructive Testing (ASNT) Use experienced Contractor Recognize and separate those areas that need immediate repair from those that are slow to change Inspection - First line of defense 8

9 U/W Tool Kit Typical VT Inspection Photo Coating Deterioration with Corrosion Inspection - First line of defense 9

10 U/W Tool Kit MT Indication of Cracking Inspection - First line of defense 10

11 U/W Tool Kit Underwater Welding Minor to Major Repair Capability Problem Hull plate cracking Corrosion plate thinning or deteriorated welds Missing hull plate Hull openings not blanked Solution Underwater wet welding Underwater dry chamber welding U/W Welding 11

12 U/W Tool Kit U/W Welding Wet Welding Ideal Conditions! 12

13 U/W Tool Kit Wet Welding NAVSEA Approved Process for ships in service Blank installation for deactivation ABS Approved Permanent or Temporary Repair Uses Repair of indications Fillet and Groove welds Installation of doubler plates Installation of blank patches Rudder and Bilge Keel Repair (dewater) Broad range of material compatibility (based on Carbon Equivalent) Carbon Steel electrode High Ni Electrode U/W Wet Welding Cost effective repairs 13

14 U/W Tool Kit Wet Welding Benefit Relatively low cost Easy access to underwater hull and appendages Does not require a dry chamber no fabrication and installation cost Cautions and Concerns Requires use of qualified procedures and welders ABS / AWS / NAVSEA Workmanship Requires metal sample analysis for procedure selection Interior ship space must be gas free, inert, or flooded Minimum visibility requirement may be a problem in brackish water Lower quality weld than dry chamber Requires preservation (U/W paint) U/W Wet Welding Cost effective repairs 14

15 U/W Tool Kit Underwater Welding Fit Up Joint Prep Underwater Welding Completed Weld U/W Wet Welding Cost effective repairs 15

16 U/W Tool Kit DDG Rudder Repair in a Dry Chamber Dry Chamber Welding Equivalent to dry dock 16

17 U/W Tool Kit Dry Chamber Welding NAVSEA Approved Process for Ships in Service ABS Approved Procedures Uses Repair of indications Fillet and Groove welds Installation of doubler plates Installation of blank patches Hull plate replacement Rudder and Bilge Keel repair (dewater) Broad range of material compatibly: Mild Steel to HY-80 Dry Chamber Welding Equivalent to dry dock 17

18 U/W Tool Kit Dry Chamber Welding Benefit Repair quality identical to dry dock repair Permanent repair Cost effective compared to dry docking Broad Range of materials Cautions and Concerns Requires use of qualified procedures and welders ABS / AWS / NAVSEA Workmanship Requires metal sample analysis for procedure selection Requires engineered, specialized cofferdam fabrication, rigging, installation Interior space must be gas free / inert Requires preservation (U/W paint) Dry Chamber Welding Equivalent to dry dock 18

19 U/W Tool Kit Dry Chamber Ready for Installation Weld Prep in Dry Chamber Dry Chamber Welding Equivalent to dry dock 19

20 U/W Tool Kit Dry Chamber Weld Root Pass with Pre-Heat Dry Chamber Welding Equivalent to dry dock 20

21 U/W Tool Kit Completed Weld from Interior of Hull Dry Chamber Welding Equivalent to dry dock 21

22 U/W Tool Kit Cutting and Burning Metal Removal Problem Need for removal of metal (plate, stiffeners, appendages) to facilitate repair Solution U/W torch: Exothermic rods, tubular rod Bulk removal of metal U/W Carbon Arc Gouging Weld Preparation Bulk Removal Mechanical Cutting Tools Diamond blade saws Water / Slurry Jets Cutting and Burning Fast and efficient 22

23 U/W Tool Kit Benefit Fast, efficient process for weld prep Cautions and Concerns Requires a very experienced operator Explosive gasses are produced proper protocol and technique required Cutting and Burning Fast and efficient 23

24 U/W Tool Kit Cofferdams Open Top, Side Mount and Overhead Problem Many repairs cannot be completed in the wet, the area must be dry Solution Specially designed temporary enclosures for dewatering and access Benefit Allows topside workers or divers to access a dry work area Broad range of maintenance and repair capability Repair quality identical to dry dock repair - permanent repair Cost effective compared to dry docking Cofferdams A dry environment for work 24

25 U/W Tool Kit Cofferdams Cautions and Concerns Requires engineered design and quality fabrication Requires hull template to fabricate seal surface Requires engineered rigging plan May require welding padeyes to the underwater hull Repair area will require preservation (U/W paint) Cofferdams A dry environment for work 25

26 U/W Tool Kit Surface Piercing Cofferdam Rigged for Installation Interior Cofferdams A dry environment for work 26

27 U/W Tool Kit Installed Ready for Work Repair Underway Cofferdams A dry environment for work 27

28 U/W Tool Kit Overhead Cofferdam Custom Shape to Suit Task Cofferdams A dry environment for work 28

29 U/W Tool Kit U/W Fairing & Coatings Problem Long term preservation and inhibiting corrosion Patching and fairing to restore contour Solution Wet applied and curing epoxy compounds including thin coatings and thick fairing material Proven technology decades of use NAVSEA Approved - Hycote, Splash Zone, Belzona ($$) Benefits Restoration of surface contour Preservation Can be applied to relatively large areas Cautions and Concerns Surface preparation and application Water temperature limited for cure U/W Fairing & Coating Compounds 29

30 U/W Tool Kit Hycote Application U/W Fairing & Coating Compounds 30

31 Maintenance & Repair Typical U/W Maintenance and Repair Tasks Hull Opening Blanking Rudder Repair (dewater) Rudder Removal Propeller Removal Hull Plate Insert / Doubler Plates Crack Arresting and Repair Clad Welding / Surfacing Anode Installation Impressed Current System Maintenance and Repair Painting and Fairing Support of Interior Hull Repairs Dry Dock Preparation (hull clean, inspection, and work scope) Full Spectrum of M & R Capabilities 31

32 USS Midway Museum Established in 2004 Problem Hull Blanks not Installed as required by NSTM CH Total Openings Requiring Blanking Based on existing docking drawing Detailed survey necessary to ensure no ShipAlt s added any openings Size Range: 5 ft by 12 ft rectangle to 12 inch diameter Solution Phased Repair 3 year effort Hull Cleaning Prior to Blank Installation Openings Prioritized Based on: Risk of leakage Location to minimize movement of the dive station Background 32

33 Planning and Preparation USS Midway Museum Pier Space / Lay Down Area Not Available barge required to support diving operations Protected Berth For Barge, but Restricted Access for Movement Load Out for Entire Ops minimal restock during work Long Lead Items Ordered /On Hand Prior to Mobilization Metal Sample Analysis for Electrode Selection procedure qualification Identify and Prepare Affected Interior Space de-water remove fuel gas free Background 33

34 USS Midway Museum Site Preparation / Mobilization 34

35 USS Midway Museum Dive Station Set Up Crane for Handling Blanks Dive Gear and Umbilicals Welding Machines Blanks Painted and Ready to Install Small Boat Fuel Generators / Power Fabrication Area Cutting and Burning Rig Port-a-Johns Work Site Layout 35

36 USS Midway Museum Heavy Fouling and Corrosion in Work Area Blank Installation - Preparation Area Prepared to Bare Metal for U/W Coating 36

37 USS Midway Museum Blank Fit Up QA Check Point photograph and VT inspection Must Match Curvature and Deformity in Hull Gap Must Meet Weld Procedure Requirement Tack Weld in Place Blank Installation 37

38 USS Midway Museum Blank Welding QA Check Point Root pass photograph and VT inspection Must Meet Workmanship Requirements Blank Installation Root Pass 38

39 USS Midway Museum Blank Welding QA Check Point photograph, VT & MT inspection Must Meet Workmanship Requirements Blank Installation Fill Pass 39

40 USS Midway Museum Blank Pressure Test QA Check Point de-water and purge with dry Nitrogen: must pass 2 psi over ambient pressure test with 10 minute hold, no leaks or pressure drop QA Check Point final video, vent to surface Blank Installation Inspection and test 40

41 USS Midway Museum Blank Installation Expect the unexpected! 41

42 USS Midway Museum Blank Installation Expect the unexpected! 42

43 USS Midway Museum Blank Installation Expect the unexpected! 43

44 USS Midway Museum Blank Installation Problem solved 44

45 USS Midway Museum Communication Daily Progress Reports Work completed Work planned Ship s Force assistance required Problems Must be a Team effort to be cost effective Progress Report and SitReps 45

46 USS Midway Museum Statistics Phoenix Welders Performed 2,439 hours of bottom time Completed 499 linear feet of 3/8 inch wet welds Installed 35 Hull Blanks Completed 1/3 of total welds required for project completion 1807 sq ft of underwater paint applied On Schedule and Within Budget Phase One All milestones completed! 46

47 New Technology Technology to Watch In water technology lags, but keeps a steady pace with surface capabilities NDT and Inspection Tools and Techniques Welding Advances Coatings and Adhesives Cathodic Protection The Next Generation of Tools 47

48 In Water Repair in lieu of Dry Docking Summary Accepted by Major Classification Societies (ABS & DNV) Accepted by the U.S. Navy Broad Spectrum of Capabilities Significant Cost Savings over Dry Docking No towing or ship movement required No lost revenue open while repairs are being conducted Phase work to fit annual budget Not a Cure All dry docking may be required Pre docking tasks at considerable savings Full hull clean Thin hull / corrosion survey Removal of damaged plate or components Defined work package reduce add on work Underwater I, M & R - An affordable solution 48

49 Conclusion Questions? 49

50 UNDERWATER SOLUTIONS WORLDWIDE Phoenix International Holdings, Inc. Contact Information: Dave McConaghay GM Pacific Region Work: Cell: Clint Levine PM USS Midway Project Work: Cell: Tim Janaitis Business Development Work: Cell: Eric Lindberg CFO / Quality Manager Work: Cell: